Heat exchange system

ABSTRACT

The present invention relates a novel heat exchange system. More particularly, the invention concerns a heat exchange system for use in bathing apparatus, including showers, bathtubs and whirlpools. Advantageously, this system is simple to install, maintain and clean and can easily be integrated in a limitless variety of bathing apparatus.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.09/850,239 filed May 7, 2001, which claims priority on U.S. ProvisionalPatent Application No. 60/202,250 filed May 5, 2000, hereby incorporatedin its entirety by reference into this application.

FIELD OF THE INVENTION

The present invention relates a novel heat exchange system. Moreparticularly, the invention relates to a heat exchange system for usewith bathing apparatus, including showers, bathtubs and whirlpools, thatis easy to install, maintain and clean.

BACKGROUND OF THE INVENTION

Heat exchange systems for use with showers or other bathing apparatusare known in the art. They are used to recover heat from hot or warmwaste water. In each of these systems, the spent water flows on one sideof a heat exchanger before flowing out into the drainage system.Incoming cold water flows on the other side of the heat exchangerelement and is thereby preheated before being mixed in a mixer with hotwater or before entering a hot water heating device to be heatedfurther.

Sample patent applications and patents in the field include thefollowing: Canadian Patent Application No. 2,566,351; Canadian PatentApplication No. 2,559,296; United States Patent Application PublicationNo. 2004/0194916; International Patent Application No. PCT/SE00/01548;International Patent Application No. PCT/US2007/019689; InternationalPatent Application No. PCT/GB2008/002129; UK Patent GB 2 052 698; GermanPatent No. DE 3319638; German Patent No. DE 3804534; German Patent No.DE 3919544; German Patent No. DE3932871; German Patent No. DE 4406971;German Patent No. DE 8600554; German Patent No. DE 19723148; GermanPatent No. DE 29709630; German Patent No. DE 29717073; German Patent No.DE 29806939; German Patent No. DE 29815304; German Patent PublicationNo. DE 202007007907; and Dutch Patent No. NL 1014215.

In many instances, the heat exchanger is installed beyond the drain ofthe bathing apparatus and thus comes into with warm waste water afterthe water has flowed through the drain. There are a number ofdisadvantages with this kind of arrangement. First, heat that mightotherwise have been captured is dissipated as it goes through the drain.Secondly, installing a heat exchanger beyond a drain unit requires theexpertise of a professional plumber, as it is usually connected directlyto the plumbing system in one manner or another. Finally, heatexchangers of this type can be inconvenient to clean, repair or replace,because they are not readily accessible.

In addition, many heat exchange devices that are currently available arebased on a coil system of some kind. Over time, the accumulation of dirtand minerals from the waste water can impede the efficiency of suchdevices. In some cases, their complexity can make maintenance and repairdifficult.

The present invention seeks to overcome some of the limitations of heatexchangers that are currently available.

SUMMARY OF THE INVENTION

Advantageously, the system of present invention has a simple and cleandesign, allowing for ready access to the heat exchange element formaintenance, repair and replacement. It is also easy to install in abathing apparatus and therefore does not necessarily require theintervention of a plumbing professional.

The present invention provides a heat exchange device to recover hotwater from bathing apparatus. The invention has particular, but notexclusive, application to showers.

The basic features of the invention include: (a) a shower or bathtubbase; and (b) a heat exchange plate made of a conductive material. Theheat exchange device may further include (c) a cover positioned over theheat exchange plate that serves as a standing platform for the batherand that compliments the shower or bathtub base. The base furtherincludes a draining element through which used water is evacuated fromthe shower or bathtub.

The heat exchange plate is positioned at the bottom of the shower orbathtub base, usually flush with the bottom surface. In one embodiment,the bather is in direct contact with the heat exchanger, eitherpartially or completely, when using the bathing apparatus.

As stated above, the heat exchanger may optionally be concealed by acover, which is manufactured in a shape and size that is suitable tocover the opening created by the base. The cover is made of anon-conductive material. In a specific embodiment, the base, heatexchange plate and cover all have a square or rectangular geometricshape.

Most of the water originating from of the showerhead or faucet of thebathing apparatus flows on top of the heat exchanger before reaching thedrainage system. The heat exchanger may be covered either fully orpartially with a non-conductive material.

The heat exchange system may include a dam that serves to control theflow of the waste water to the drain of the bathing apparatus. Byslowing down the flow, the warm waste water is kept in contact with theheat exchange plate for a longer duration, enhancing heat transfer.Other elements may be substituted for or used with the dam to achievethis purpose, such as channels or dividing elements, as would beappreciated by a person of skill in the art.

In any embodiment, the heat exchanger is part of the bathing apparatusand the entire assembly is water tight.

Other objects, advantages and features of the present invention willbecome apparent upon reading of the following non-restrictivedescription of embodiments thereof, given by way of example only withreference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows (A) an assembled view of a first embodiment of the heatexchange system of the present invention and (B) an exploded view ofthis system;

FIG. 2 shows (A) an alternative assembled view of the heat exchangersystem shown in FIG. 1, and (B) an exploded view of this system;

FIG. 3 shows (A) a second alternative assembled view of the heatexchanger system shown in FIG. 1, and (B) an exploded view of thissystem;

FIG. 4 shows (A) a third alternative assembled view of the heatexchanger system shown in FIG. 1, and (B) an exploded view of thissystem;

FIG. 5 shows a second embodiment of the heat exchange system of thepresent invention, wherein: (A) is a top plan view of the system, (B) isa side view of the system taken along line A-A of FIG. 5(A); and (C) isan exploded view of the system;

FIG. 6 shows an alternative to the embodiment shown in FIG. 5, wherein:(A) is a top plan view of the system, (B) is a side view of the systemtaken along line A-A of FIG. 6(A); and (C) is an exploded view of thesystem;

FIG. 7 shows a second alternative to the embodiment shown in FIG. 5,wherein: (A) is a top plan view of the system, (B) is a side view of thesystem taken along line A-A of FIG. 7(A); and (C) is an exploded view ofthe system;

FIG. 8 shows a third alternative to the embodiment shown in FIG. 5,wherein: A) is a top plan view of the system, (B) is a side view of thesystem taken along line A-A of FIG. 8(A); (C) is a side view of thesystem taken along line B-B; (D) is a side view of the system takenalong line C-C of FIG. 8(A); (E) is a perspective view of the systemfully assembled; and (F) is a perspective view of the system without itscover;

FIG. 9 shows a third embodiment of the heat exchange system of thepresent invention; wherein: (A) is a top plan view of the system, (B) isa side view of the system taken along line A-A of FIG. 9(A); and (C) isa perspective view of the system fully assembled;

FIG. 10 shows an alternative to the embodiment shown in FIG. 9, wherein:(A) is a top plan view of the system, (B) is a side view of the systemtaken along line A-A of FIG. 10(A); and (C) is an exploded view of thesystem; and

FIG. 11 shows a fourth embodiment of the heat exchange system of thepresent invention, wherein: (A) is a top plan view of the system, (B) isa side view of the system taken along line A-A of FIG. 11(A); and (C) isa perspective, partially exploded view of the system.

DETAILED DESCRIPTION OF THE INVENTION

As will be described more particularly below, the invention comprisesfour embodiments, and these embodiments can include additional features.

Referring now to FIG. 1, there is shown a first embodiment of theinvention wherein the heat exchange system is generally designated bythe number 10. The system comprises a bathing apparatus 2, illustratedhere as a tray-like element that is convenient for a shower. The systemfurther comprises a heat exchange element 4, which is in the generalform of a plate, and a gasket 3 for sealing the heat exchanger withinthe bathing apparatus. In order to allow waste water to be eliminatedfrom the bathing apparatus 2, a drain 8 is provided.

In operation, the heat exchange element 4 is connected to a cold watersource (not shown). When warm from the showerhead or warm waste waterfrom the bather falls onto the heat exchange element 4, heat from thewater is captured by the heat exchange element and used to warm the coldwater that flows through the body of the heat exchanger element, inkeeping with heat exchange principles known in the art. The cold water,which has now been partially heated by the captured energy from thewaste water, exits from the heat exchanger (not shown), where it isdirected to a mixer or to a hot water tank, once again in keeping withheat exchange principles known in the art.

Use of a heat exchange system as described above results in energyconservation and is thus ecological sound. The simplicity of the heatexchange system exemplified here has several advantages. It facilitatescleaning and maintenance of the bathing system and, in distinction towhat is currently available commercially, is very simple to installand/or replace.

The heat exchange element 4 is conveniently shown as a plate orplate-like structure having a relative large surface area. The surfacearea and the thickness of the plate may be altered or otherwise designedwith a view to increasing surface area exposure to warm shower or wastewater to maximize the efficiency of the heat exchange. While illustratedas a rectangle in FIG. 1, the heat exchange element 4 can in practiceassume any geometry that is required to fit within the shape of adesired bathing apparatus.

The heat exchange element 4 may be made of any heat conductive material,including, without limitation, any metal, concrete or stones, compositescomprising a polymer, or a conductive material, like graphite.

FIG. 2 shows an alternative version of the heat exchange systemillustrated in FIG. 1. In this version, a non-conductive material 9,shown here as a series of circles, is applied on the surface of the heatexchange element 4 and serves as a barrier between the bather and theheat exchange element. It will be appreciated that the shape, size,configuration and/or pattern of the non-conductive material 9 is(are)limited only by creativity. The non-conductive material can be made ofwood, rubber, plastic or any other synthetic material that is suitablefor the desired purpose. It may in some instances serve the dual purposeof preventing the bather from slipping while in the bathing apparatus.

FIG. 3 shows a slightly modified version of the heat exchange systemillustrated in FIGS. 1 and 2. In this specific version, two small “dams”or dam-like elements 12 have been introduced in the bottom of thebathing apparatus in the vicinity of the drain 8 in order to controlwater flow through the controlled opening 14. Warm shower or waste waterremains in contact with the heat exchange element 4 for a longerduration than in the absence of the dams 12, which enhances heattransfer from the water to the heat exchange element.

A number of dams or dam-like elements 12 can be introduced into abathing apparatus 2 so as to create one, or more than one, controlledopening(s) 14. This allows the discharge of warm waste water to becontrolled, and therefore allows modulation of the effective heattransfer. The dams or dam-like elements 12 may be integral to thebathing apparatus 2 or added to said bathing apparatus as separateelements thereto.

FIG. 4 is yet another modified version of the heat exchange systemillustrated in FIGS. 1-3. This version combines the dams or dam-likeelements 12 of the heat exchange system of FIG. 3 with thenon-conductive material 9 of FIG. 2.

Turning now to FIGS. 5 to 8, an alternative embodiment of the inventionis presented. As illustrated in FIG. 5, this embodiment consists of aheat exchange system 20 comprising a bathing apparatus 22, a heatexchange element 24 and a cover 29. This cover is positioned over theheat exchange element and serves to enclose the bathing apparatus 22. Adrain 28 is included in the base of the bathing apparatus to allow thewarm shower or waste water to leave the system. The heat exchangeelement optionally includes one or more spacers 25, as illustrated inFIGS. 5 to 8. The spacers create a distance between the heat exchangeelement and the cover 29.

The cover 29 is made of any non-conductive material. Suitablenon-conductive materials include, without limitation, plastic, compositematerials, wood or wood-like materials or materials including wood(which may optionally be imbibed with a preservative, such as Accoya® ora resin-impregnated material), bamboo, organic materials, glass orceramic. The cover 29 may optionally include openings 30 or theequivalent thereof to enhance water flow from the cover's surface to theheat exchange element 24. These openings 30 are also used to assist inthe lifting of the cover from the bathing apparatus for cleaning ormaintenance purposes.

FIG. 6 shows a slightly different embodiment from that appearing in FIG.5 wherein two “dams” or dam-like elements 32, similar to those in FIGS.3 and 4, have been included to control water flow to the drain. Acontrolled opening (not shown) analogous to that in FIGS. 3 and 4 servesto delay flow of the shower and waste water towards the drain.

FIG. 7 shows another variation of the heat exchange systems illustratedin FIGS. 5 and 6. In this version, a series of discontinuous dividers34, or the equivalent thereof, have been included within the bathingapparatus 22. The purpose of these discontinuous dividers 34 is to keepwarm shower and waste water within the confines of the bathing apparatusfor a longer time in order to enhance heat transfer to the heat exchangeelement 24. The buoys or equivalent thereof may be an integral part ofthe bathing apparatus 24 (i.e., cast at the same time as the bathingapparatus itself) or otherwise attached as a separate element to thebathing apparatus.

FIG. 8 shows yet another variation of the heat exchange systems shown inFIGS. 5 and 6. This variation is very similar to that shown in FIG. 7,but includes a water channel 36 that surrounds the opening of thebathing apparatus 22 where the heat exchange element 24 is positioned.Warm shower or waste water accumulates in this channel 36 in proximityto the heat exchange element 24. As a result, the warm shower or wastewater remains in contact with the heat exchange element for a longertime, enhancing heat transfer and thereby increase the overallefficiency of the heat exchange system.

FIGS. 9 and 10 show a third embodiment of the heat exchange system ofthe present invention. In this embodiment, the heat exchange system 50comprises a bathing apparatus 54 that is made of a conductive material.The bathing apparatus is the heat exchange element in this particularembodiment. The bathing apparatus 54 may be comprised of one or moreelements, wherein each element is made of a conductive material. Asshown in FIG. 9, a surface 56 is made of the same conductive material asthe bathing apparatus 54, or of a different conductive material, but isfully attached to the bathing apparatus. This surface 56 is optionallycovered, partially or totally, with a non-conductive material. A gasketor other sealing means may be optionally included in order to ensurethat the bathing apparatus is water-tight.

In the variation of this embodiment of the invention shown in FIG. 10, asurface 57 is made of a non-conductive material. This surface 57 isremovable from the bathing apparatus 54 and is made of a non-conductivematerial, or of a conductive material that is partially or totallycovered with a non-conductive material.

As shown in FIG. 9, the heat exchange system 50 further includes a drain58. Alternatively, as shown in FIG. 10, water from the shower may flowin a channel 59 running between the surface 57 and the bathing apparatus54. The drain 58 is located beneath the surface in this version of theembodiment of the invention.

FIG. 11 shows a fourth embodiment of the heat exchange system of thepresent invention. In this embodiment, the heat exchange system 70comprises a bathing apparatus 72 and one or more heat exchange elements74. The top of the bathing apparatus 76 may be fully integrated with itsbase, or optionally, a separate cover. The heat exchange elements arenot flat like those in the other embodiments of the invention butconsist of rectangles whose width, height and length can be modified soas to increase effective surface area and hence promote heat exchange.This embodiment may offer a solution that is more suitable to the stylesof certain baths and showers.

As with the embodiment shown in FIGS. 9 and 10, the embodiment of theinvention shown in FIG. 11 comprises a cover 76 made of a non-conductivematerial. This cover can include an opening 78 that is positioned eitherin the cover 76 or in the bathing apparatus 72. Once again, this openingfacilitates access to the system for cleaning and maintenance purposes.

In any embodiment, the heat exchanger is part of the bathing apparatusand the entire assembly is water tight.

The embodiments of the invention all have the advantage of simplicity.Installing a heat exchange system as described above can be convenientlydone in an existing bathing system or in a new one. Features of theinvention, such as the limited number of components and their ability tobe removed from each other in a relatively easy manner, allowing forready cleaning, maintenance and replacement.

In addition, the selection of embodiments allows for even greaterflexibility. Depending on the style and function of the bathingapparatus, a heat exchange system can be selected to best accomplishheat exchange.

The above-described embodiments of the invention are intended to beexamples only. Variations, alterations and modifications can be made tothe particular embodiments described herein by those of skill in the artwithout departing from the scope of the invention, as defined in theappended claims.

1. A heat exchange system comprising a bathing apparatus with a drainelement and a heat exchange element having a generally flat surface,wherein said heat exchange element is positioned against the bottomsurface of said bathing apparatus and serves a platform surface uponwhich a bather can stand or sit.
 2. A heat exchange system as defined inclaim 1, further comprising a gasket to seal said heat exchange elementwithin said bathing apparatus.
 3. A heat exchange system as defined inclaim 1, wherein a non-conductive material is applied partially orcompletely on the surface of the heat exchange element.
 4. A heatexchange system as defined in claim 1, further comprising one or moredams or dam-like elements.
 5. A heat exchange system comprising abathing apparatus with a drain element, a heat exchange element having agenerally flat surface, wherein said heat exchange element is positionedagainst the bottom surface of said bathing apparatus and a cover made ofa non-conductive material serving as a platform surface upon which abather can stand or sit.
 6. A heat exchange system as defined in claim5, wherein said bathing apparatus includes one or more spacers.
 7. Aheat exchange system as defined in claim 5, wherein said cover is madeof one piece or multiple pieces of non-conductive material.
 8. A heatexchange system as defined in claim 7, wherein said cover is made ofmultiple pieces having different thicknesses.
 9. A heat exchange systemas defined in claim 7, wherein said cover is made of multiple pieceshaving similar thicknesses.
 10. A heat exchange system as defined inclaim 5, wherein said cover includes one or more openings or theequivalent thereof to allow water to reach said heat exchange element.11. A heat exchange system as defined in claim 5, further comprising oneor more dams or dam-like elements.
 12. A heat exchange system as definedin claim 5, further comprising a series of discontinuous dividers or theequivalent thereof.
 13. A heat exchange system as defined in claim 5,further comprising a water channel that surrounds the opening of thebathing apparatus.
 14. A heat exchange system comprising a bathingapparatus with a drain element, wherein said bathing apparatus is madeof a conductive material that is suitable for heat exchange and whereinsaid bathing apparatus includes a platform surface upon which a bathercan stand or sit.
 15. A heat exchange system as defined in claim 11,wherein said platform surface is made of or at least partially coveredwith a non-conductive material.
 16. A heat exchange system as defined inclaim 11, wherein said system includes a surrounding channel or theequivalent thereof.
 17. A heat exchange system comprising a bathingapparatus with a drain element, and one or more heat exchange elementswithin said bathing apparatus, wherein said bathing apparatus includes aplatform surface upon which a bather can stand or sit.
 18. A heatexchange system as defined in claim 17, wherein said heat exchangeelements are generally rectangular in shape.
 19. A heat exchange systemas defined in claim 1, wherein said heat exchange elements is a metal,concrete, stone, a composite comprising a polymer or graphite.
 20. Aheat exchange system as defined in claim 5, wherein said non-conductivematerial is plastic, a composite material, wood, a wood-like material, amaterial including wood, bamboo, organic materials, glass or ceramic.21. A heat exchange system as defined in claim 20, wherein said wood isoptionally treated.
 22. A heat exchange system as defined in claim 1,which is water tight.
 23. A heat exchange system as defined in claim 1,which is part of a shower, bath or whirlpool.
 24. A heat exchangersystem as defined in claim 1, which has at least one inlet and oneoutlet for water to flow inside said heat exchange element before beingsent to a mixer or hot water tank.
 25. A heat exchanger system asdefined in claim 1, which has at least one inlet and one outlet forwater to flow inside said heat exchange element before being sent to areservoir.
 26. A heat exchange system comprising a bathing apparatus anda heat exchange element, wherein said heat exchange element is in thebottom of said bathing apparatus, flush with the bottom surface thereofand covered with a non conductive material so that a bather is notdirectly in contact with said heat exchange element.
 27. A heat exchangesystem as defined in claim 26, wherein water accumulates behind a damwith at least one controlled opening before reaching the drainage systemwithout restriction.
 28. A heat exchange system comprising a bathingapparatus and a heat exchange element, wherein said heat exchangeelement is in the bottom of said bathing apparatus, flush with thebottom surface, and wherein a bather is in direct contact with said heatexchange element.
 29. A heat exchange system as defined in claim 28,wherein water accumulates behind a dam with at least one controlledopening before reaching the drainage system without restriction.
 30. Aheat exchange system comprising a bathing apparatus and a heat exchangeelement, wherein said heat exchange element is in the bottom of saidbathing apparatus, flush with the bottom surface thereof and coveredwith a non conductive material so that a bather is not directly incontact with said heat exchange element, and wherein all the waste wateris channeled away from the drain in said bathing apparatus in order tohave all the waste water flow on said heat exchange element beforereaching the drainage system without restriction.
 31. A heat exchangesystem comprising a bathing apparatus and a heat exchange element,wherein said heat exchange element is in the bottom of said bathingapparatus, flush with the bottom surface thereof and covered with a nonconductive material so that a bather is not directly in contact withsaid heat exchange element, wherein all the waste water is directed toflow on at least one side of said heat exchange element, and whereinwater waste water accumulates behind one or more dams or dam-likeelements with at least one controlled opening before reaching the drainwithout restriction.
 32. A heat exchange system comprising a bathingapparatus and a heat exchange element, wherein said bathing apparatus issurrounded with a channel and the bottom of said channel is the heatexchanger, and wherein all the waste water is channeled away from thedrain in said bathing apparatus in order to have all the waste waterflow on said heat exchange element before reaching the drainage systemwithout restriction.